Installation and Operation Manual
PosiLok ™
Suspension Docking Feature for Trailer Air-Ride Suspensions
„
CBX40/CB4000/CBX69
XL-AS20001BM-en-US Rev B
Contents
Contents ......................................................................... Page
Introduction ......................................................................... 2
Warranty .............................................................................. 2
Notes, Cautions, and Warnings ............................................. 2
Section 1 – General Safety Instructions ................................ 3
Section 2 – PosiLok™ Decal Requirements ............................ 4
Section 3 – CBX40 Model Identification ............................... 5
Section 4 – CBX40 Model Nomenclature .............................. 5
Section 5 – CBX40 Fusion Model Identification .................... 6
Section 6 – CBX40 Fusion Model Nomenclature ................... 6
Section 7 – CB4000 Model Identification .............................. 7
Section 8 – CB4000 Model Nomenclature ............................ 7
Section 9 – CBX69 Model Identification ............................... 8
Section 10 – CBX69 Model Nomenclature ............................ 8
Contents ......................................................................... Page
Section 11 – Welding Standards ........................................... 9
Section 12 – Suspension Model Identification .................... 10
Section 13 – Additional Verification Procedures .................. 10
PosiLok™ Exploded View and Parts List ............................... 11
Section 14 – Flipper Plate Installation ................................ 12
Section 15 – Actuator Chamber Installation ........................ 12
Section 16 – Air System Connection Overview .................... 13
Section 17 – PosiLok™ Engage Procedures .......................... 16
Section 18 – PosiLok™ Disengage Procedures ..................... 16
Section 19 – Ride Height Adjustment ................................. 17
Section 20 – Height Control Valve Performance Check ........ 18
Section 21 – Troubleshooting ............................................. 19
Introduction
This manual provides information necessary for the
installation, and operation of the SAF-HOLLAND® PosiLok™
suspension feature for CBX40, CB4000 and CBX69 Trailer
Air-Ride Suspensions.
The PosiLok™ docking assembly was designed to provide
additional stability to the air ride suspension during loading
or unloading of a trailer. The proper functional use of the
system is dependent on proper installation of the hardware.
™
The PosiLok uses air drawn from the truck-tractor air system
to operate the PosiLok™ actuator. The PosiLok™ feature
automatically engages when the parking brakes are set. This
feature automatically disengages when the trailer brakes are
released and allows the height control valve to regulate the
air pressure and return the suspension to ride height.
Warranty
Refer to the complete warranty for the country in which
the product will be used. A copy of the written warranty
is included with the product and can be found on the
SAF-HOLLAND® website (www.safholland.com).
Notes, Cautions, and Warnings
You MUST read and understand all of the safety procedures
presented in this manual before starting any work on
the suspension.
Proper tools MUST be used to perform the maintenance and
repair procedures described in this manual. Many of these
procedures require special tools.
NOTE: In the United States, workshop safety requirements
are defined by federal and/or state Occupational
Safety and Health Act. Equivalent laws may exist
in other countries. This manual is written based
on the assumption that OSHA or other applicable
employee safety regulations are followed by the
location where work is performed.
IMPORTANT: Read this manual before using this
product. Keep this manual in a safe
location for future reference.
Failure to follow the instructions and
safety precautions in this manual can
result in death or serious injury.
Throughout this manual, you will notice the terms “NOTE”,
“IMPORTANT”, “CAUTION”, and “WARNING” followed by
important product information. So that you may better
understand the manual, those terms are as follows:
NOTE: Includes additional information to enable accurate
and easy performance of procedures.
IMPORTANT: Includes additional information that
if not followed could lead to hindered
product performance.
Used without the safety alert symbol,
indicates a potentially hazardous
situation which, if not avoided, could
result in property damage.
Indicates a potentially hazardous
situation which, if not avoided, could
result in minor or moderate injury.
Indicates a potentially hazardous
situation which, if not avoided, could
result in death or serious injury.
2
XL-AS20001BM-en-US Rev B · 2014-04-22 · Amendments and errors reserved. © SAF-HOLLAND, Inc.
General Safety Instructions
1. General Safety Instructions
Read and observe all Warning and Caution hazard alert
messages in this publication. They provide information
that can help prevent serious personal injury, damage to
components, or both.
Failure to properly support the vehicle
and axles prior to commencing work could
create a crush hazard which, if not avoided,
could result in death or serious injury.
Failure to follow manufacturer’s instructions
regarding spring pressure or air pressure
control may allow uncontrolled release of
energy which, if not avoided, could result
in death or serious injury.
Please observe the following safety instructions in order to maintain
the operational and road safety of the suspension system.
1.
Before operating vehicle, ensure that the maximum
permissible axle load is NOT exceeded and that the load
is distributed equally and uniformly.
2.
The PosiLok™ feature is intended for on-highway use
only. In the event the PosiLok™ is utilized in an off-road
application, observe the operating recommendation of
the trailer manufacturer for off-road operation of the
installed axles.
3.
All suspension and axles systems require routine service,
inspection and maintenance in order to maintain optimum
performance and operational safety as well as an opportunity
to recognize wear.
4.
In the event of suspension air pressure loss, quickly
reduce speed as safely as possible and remove the
vehicle from traffic. If unable to remove vehicle from
traffic, follow DOT safety requirements regarding
emergency situations.
5.
Contact a qualified towing and/or service company to
assist in repairing vehicle or to move it to a qualified
repair facility. DO NOT operate the vehicle in the absence
of suspension air pressure.
Operating the vehicle without proper air
pressure can cause tire failure, fire, or loss
of vehicle control which, if not avoided
could result in death or serious injury.
We highly recommend the use of only SAF-HOLLAND®
Original Parts.
A list of SAF-HOLLAND® technical support locations to supply
SAF-HOLLAND® Original Parts can be found at www.safholland.us
or contact SAF-HOLLAND® Customer Service at 888-396-6501.
Updates to this manual will be published as necessary online
at www.safholland.us.
IMPORTANT: The definition of OFF-ROAD means driving
on non-asphalt/non-concrete routes, e.g.
gravel roads, agricultural and forestry tracks,
on construction sites and in gravel pits.
IMPORTANT: Off-road operation of axles beyond
the approved application design could
result in damage and impair suspension
system performance.
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3
Decal Requirements
2. PosiLok™ Decal Requirements
The following decals MUST be installed on the trailer and
MUST be in plain sight of the operator:
„
Posilok™ Misuse Caution Decal: XL-AR437 (Figure 1).
„ Air
Up Caution Decal: XL-AR439 (Figure 2).
It is the responsibility of the end user to periodically inspect
all decals and ensure that they are clean and completely legible.
If any labels are missing, loose, damaged or difficult to read,
contact SAF-HOLLAND® Customer Service at 888-396-6501
to order replacements immediately.
Figure 1
CAUTION
Failure to check for proper PosiLok™ position
could result in vehicle / suspension damage.
Copyright © 2011 #SAF-HOLLAND, Inc.
www.safholland.us
BEFORE MOVING TRAILER:
WHEN TRAILER PARKED:
Check that the
PosiLok™ is in
the UP position.
Check that the
PosiLok™ is in
the DOWN position.
PosiLok™
UP
PosiLok™
DOWN
XL-AR437
Figure 2
CAUTION
Suspension system must fully air up before moving trailer. Failure to wait before moving trailer
could result in suspension and/or slider damage.
Copyright © 2011 #SAF-HOLLAND, Inc.
4
www.safholland.us
XL-AR439
XL-AS20001BM-en-US Rev B · 2014-04-22 · Amendments and errors reserved. © SAF-HOLLAND, Inc.
Model Identification
3. CBX40 Model Identification
The CBX40 suspension serial tag is located on the rear
crossmember (Figure 3).
Figure 3
TAG LOCATED ON
REAR CROSSMEMBER
NOTE: Refer to the serial number tag attached to the slider
rear crossmember for information (Figure 3).
NOTE: If the suspension serial tag is not legible or is not
available, you can identify your suspension model
by the appearance of the equalizing beam. The
CBX40 model will have a full cast beam with no
hole forward of the axle and a 5.75" round axle
(Figure 3).
FULL CAST BEAM
NOTE: This manual applies to the suspension models
listed on the front cover. However, we urge you to
determine your specific model number, write that
information below and refer to it when obtaining
information or replacement parts (Figure 4).
4. CBX40 Model Nomenclature
Figure 4
The sample tag shown will help you interpret the information
on the SAF-HOLLAND®, Inc. serial number tag. The model
number is on the first line along with the suspension capacity.
The second line contains the part number and the serial
number (Figure 4).
SAF-HOLLAND, INC.
MODEL NO.
CB X 40 - 48 16
PART NO.
CAPACITY (LBS)
SERIAL NO.
CONSULT SPECIFICATION FOR CAPACITY AND RECOMMENDED APPLICATION.
Ride Height
15.5" (393 mm)
16" (406 mm)
16.5" (419 mm)
17" (432 mm)
18" (445 mm)
Slider Box Width
42" (1067 mm) Wide
48" (1219 mm) Wide
54" (1372 mm) Wide
Axle Capacity
Suspension Series
40,000 Tandem
5.75" Diameter Premium Axle
CB Slider
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5
Model Identification
5. CBX40 Fusion Model Identification
The CBX40 Fusion suspension serial tag is located on the rear
crossmember (Figure 5).
Figure 5
TAG LOCATED ON
REAR CROSSMEMBER
NOTE: Refer to the serial number tag attached to the slider
rear crossmember for information (Figure 5).
HOLE FORWARD OF
AXLE AND WELDED
LOWER AIR SPRING
MOUNTING PLATE
NOTE: If the suspension serial tag is not legible or is not
available, you can identify your suspension model
by the appearance of the equalizing beam. The
CBX40 Fusion model will have a cast beam with
a hole forward of the axle and a lower air spring
mounting plate welded to it (Figure 5).
NOTE: This manual applies to the suspension models
listed on the front cover. However, we urge you to
determine your specific model number, write that
information below and refer to it when obtaining
information or replacement parts (Figure 6).
6. CBX40 Fusion Model Nomenclature
Figure 6
The sample tag shown will help you interpret the information
on the SAF-HOLLAND®, Inc. serial number tag. The part number
is on the first line. The model number along with the suspension
capacity are on the second line. The third line contains the
serial number (Figure 6).
CB X 40 - 48 16
Ride Height
15.5" (393 mm)
16" (406 mm)
16.5" (419 mm)
17" (432 mm)
18" (445 mm)
Slider Box Width
42" (1067 mm) Wide
48" (1219 mm) Wide
54" (1372 mm) Wide
Axle Capacity
Suspension Series
40,000 Tandem
5.75" Diameter Premium Axle
CB Slider
6
XL-AS20001BM-en-US Rev B · 2014-04-22 · Amendments and errors reserved. © SAF-HOLLAND, Inc.
Model Identification
7. CB-4000 Model Identification
The CB-4000 suspension serial tag is located on the rear
crossmember (Figure 7).
Figure 7
TAG LOCATED ON
REAR CROSSMEMBER
NOTE: Refer to the serial number tag attached to the slider
rear crossmember for information (Figure 7).
NOTE: If the suspension serial tag is not legible or is not
available, the suspension model can be identified
by the appearance of the equalizing beam. The
CB-4000 model will have a full cast beam with a
5" round axle (Figure 7).
FULL CAST BEAM
NOTE: This manual applies to the suspension models
listed on the front cover. It is Recommended that
the specific model number is recorded below
and refered to when obtaining information or
replacement parts (Figure 8).
8. CB-4000 Model Nomenclature
Figure 8
The sample tag shown will help interpret the information on
the SAF-HOLLAND®, Inc. serial number tag. The model number
is on the first line along with the suspension capacity. The
second line contains the part number and the serial number
(Figure 8).
SAF-HOLLAND, INC.
MODEL NO.
CB - 4000 - 48 16
PART NO.
Ride Height
15.5" (393 mm)
16" (406 mm)
16.5" (419 mm)
17" (432 mm)
18" (445 mm)
CAPACITY (LBS)
SERIAL NO.
CONSULT SPECIFICATION FOR CAPACITY AND RECOMMENDED APPLICATION.
Slider Box Width
42" (1067 mm) Wide
48" (1219 mm) Wide
Axle Capacity
Suspension Series
40,000 Tandem
CB Slider
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7
Model Identification
9. CBX69 Model Identification
The CBX69 Fusion suspension serial tag is located on the rear
crossmember (Figure 9).
Figure 9
TAG LOCATED ON
REAR CROSSMEMBER
NOTE: Refer to the serial number tag attached to the slider
rear crossmember for information (Figure 9).
NOTE: If the suspension serial tag is not legible or is not
available, the suspension model can be identified
by appearance. The CBX69 will be installed on a
tri-axle sliding sub-frame and have a 5.75" round
axle, (Figure 9).
NOTE: This manual applies to the suspension models
listed on the front cover. It is Recommended that
the specific model number is recorded below
and refered to when obtaining information or
replacement parts (Figure 10).
10. CBX69 Model Nomenclature
Figure 10
The sample tag shown will help interpret the information on
the SAF-HOLLAND®, Inc. serial number tag. The part number
is on the first line. The model number along with the suspension
capacity are on the second line. The third line contains the
serial number (Figure 10).
CB X 69 - 48 16
Ride Height
16" (406 mm)
16.5" (419 mm)
17" (432 mm)
18" (445 mm)
Slider Box Width
42" (1067 mm) Wide
48" (1219 mm) Wide
54" (1372 mm) Wide
Axle Capacity
Suspension Series
69,000 Tridem
5.75" Diameter Premium Axle
CB Slider
8
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Weld Standards
11. Welding Standards
11.1 Scope
This SAF® suspension has been designed to be installed on a
trailer with no welding required. When welding is required for
suspension repairs, observe the requirements below. Customers
may not weld on an SAF® suspension without our prior approval,
including the application of the American Welding Society standards
by SAF-HOLLAND® engineering. This specification applies to
all components supplied by SAF-HOLLAND®, and its products.
The customer assumes all responsibility for weld integrity if
weld material and procedure differ from those listed below.
11.2 Workmanship
All welding on SAF-HOLLAND® products MUST be performed
by a welder qualified according to the appropriate AWS
standard for the weld being made or an equivalent standard.
It is the responsibility of the customer to provide good
workmanship when welding on SAF-HOLLAND® products.
11.3 Material
Items to be welded that are made from low carbon or high-strength
alloy steel are to be welded with AWS filler metal specification
AWS A5.18, filler metal classification ER-70S-3, ER-70S-6 or
equivalent unless specified on the installation drawing.
The recommended welding gas for gas metal arc welding
(GMAW) is 90% Argon/10% CO2. If a different gas is used,
welds MUST comply with penetration requirements shown
(Figure 11). Where the installation drawing specifies
different than above, the drawing shall prevail.
11.4 Procedures
Tack welds used for positioning components are to be
located in the center of the final weld, where practical. Tack
weld should be completely fused to the finish weld. DO NOT
break arc at the end of the weld. Back up all finish welds
at least 1/2" (12.7 mm) or a sufficient amount to prevent
craters at the end of the weld. Where weld is shown to go
around corners, it is assumed the corner represents a stress
concentration area. DO NOT start or stop weld within 1" (25.4 mm)
of the corner. Particular care should be taken to prevent
undercutting in this area.
11.5 Weld Size
If weld size is not specified, the effective throat of the weld
MUST NOT be smaller than the thinnest material being
welded (Figure 11).
NOTE: Any substitution for filler material from the above
standard MUST comply, as a minimum, with the
following mechanical properties:
Tensile Strength - 72k psi (496 MPa)
Yield Strength - 60k psi (414 MPa)
$IBSQZ7/PUDIGUMCT/tN
BUo F (-17.7o C)
% Elongation - 22%
Figure 11
PENETRATION AS MEASURED
THROUGH SEAM
LACK OF FUSION OF
ANY KIND IN THIS AREA
IS NOT ACCEPTABLE AT
ANY TIME
TARGET PENETRATION TO BE
10% OF THINNEST MATERIAL
FROM INTERSECTION OF FILLET
AS SHOWN
TARGET PENETRATION
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9
Model Verification
12. Suspension Model Verification
Figure 12
IMPORTANT: The correct PosiLok™ assembly for the
suspension ride height MUST be installed.
Various suspension ride heights require
different assemblies with different flipper
plate heights. Verify ride height before
installation (Figure 12). Refer to Table 1
below or call SAF-HOLLAND® Customer
Service at 888-396-6501.
1.
CBX40 FUSION ILLUSTRATED
0.25"
(6 mm)
“A”
RIDE HEIGHT
1" (25 mm)
MINIMUM
CLEARANCE
If the serial tag is not legible or is not available, verify
the ride height by measuring the PosiLok™ flipper plate
height (Figure 12) and compare it to the ride height
(Table 1). If the unit is not equipped with a PosiLok™
feature, refer to Section 10.
NOTE: “A” dimension does not include mounting plate.
Table 1
RIDE HEIGHT
CBX40, CB4000 “A”
FLIPPER PLATE HEIGHT
CBX40 FUSION “A”
FLIPPER PLATE HEIGHT
CBX69 “A”
FLIPPER PLATE HEIGHT
CBX40/CB4000 - 15.5
15.5" (394 mm)
7.5" (191 mm)
6.31" (160 mm)
6.75"(171 mm)
CBX40/CB4000/CBX69 - 16
16" (406 mm)
8.0" (203 mm)
6.75" (171 mm)
7.25"(184 mm)
CBX40/CB4000/CBX69 - 16.5
16.5" (419 mm)
8.5" (216 mm)
7.25" (184 mm)
7.75"(197 mm)
CBX40/CB4000/CBX69 - 17
17" (432 mm)
8.9" (229 mm)
7.75" (197 mm)
8.42"(214 mm)
CBX40/CB4000/CBX69 - 18
18" (457 mm)
9.75" (247 mm)
8.69" (221 mm)
9.42"(239 mm)
MODEL NUMBER
NOTE: Flipper plate height does not include mounting plate.
13. Additional Verification Procedures
1.
Measure the height of the spacer under the air spring
(Figure 13) and compare it to a value in the Spacer
Height Charts below.
2.
After determining the spacer height, determine the shock
part number and cross reference the information (Table 2)
to confirm the model number.
Table 2 SPACER HEIGHT CHARTS
CBX40 FUSION ILLUSTRATED
MODEL NUMBER
BRACKET HEIGHT
HEIGHT
CBX40/CB4000/CBX69* - 15.5
10.0" (254 mm)
–
CBX40/CB4000/CBX69* - 16
10.0" (254 mm)
0.188" (4 mm)*
CBX40/CB4000/CBX69* - 16.5
10.0" (254 mm)
0.62" (15 mm)
CBX40/CB4000/CBX69* - 17
10.0" (254 mm)
1.22" (31 mm)
CBX40/CB4000/CBX69* - 18
10.0" (254 mm)
–
* No spacer for 16" Fusion and CBX69.
10
Figure 13
FRAME
BRACKET
HEIGHT
AIR SPRING
SPACER
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PosiLok ™ Exploded View
BOLTS ARE PRE-WELDED
TO FRAME RAILS
5
BOLTS ARE PRE-WELDED
TO FRAME RAILS
5
1
2
4
6
7
3
2
POSILOK™ PARTS LIST
ITEM
DESCRIPTION
QTY.
1
™
PosiLok Flipper Plate Assembly
1
2
Lock Nut 1/2"-13
4
3
Actuator Chamber
1
4
1/2" Clevis-Assembly with 1/2" Pin
1
5
Block
2
6
Lock Nut 1/2"-20
2
7
Lock Washer 1/2"
2
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11
Installation
14. Flipper Plate Installation
NOTE: Prior to installing a PosiLok™ system, make sure
all mounting surfaces and bolts are clean and free
of obstructions.
1.
Figure 14
BOLTS ARE PRE-WELDED
TO FRAME RAILS
Locate the pre-welded bolts in the bottom of the frame
rail above the rear axle. Install the flipper plate assembly
so bolts protrude through the end plate holes of the flipper
plate assembly. Tighten nuts evenly and apply a final
UPSRVFPGGUMCT/tN
PODMFBOBOE
lubricated threads (Figure 14).
IMPORTANT: PosiLok™ flipper plate assembly should
rotate freely without binding (Figure 15).
POSILOK™ FLIPPER
PLATE ASSEMBLY
NUTS
NUTS
15. Actuator Chamber Installation
1.
Attach actuator chamber to mounting bracket on slider
box rear crossmember (Figure 15) with the two lock
XBTIFSTBOEOVUT5PSRVFOVUTUPGUMCT/tN
Figure 15
IMPORTANT: Flipper plate MUST be completely down when
attaching actuator push rod (Figure 16).
LOCK NUT
LOCK WASHER
ACTUATOR
CHAMBER
MOUNTING
BRACKET
ACTUATOR
CHAMBER
Figure 16
CBX40 FUSION ILLUSTRATED
1" MIN. (25 mm)
CLEARANCE GAP
REQUIRED
12
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Installation
2.
3.
Adjust clevis and jam nut on push rod so clevis mounting
hole is 1/4" (6 mm) to 1/3"(8 mm) short of cam mounting
hole to cause tension on actuator return spring (Figure 17).
Figure 17
BLOCK
Pull the actuator push rod out (Arrow A) so that the hole
in the cam mounting hole aligns with the clevis mounting
hole. Install the clevis pin and secure it with cotter pin
(Figure 17).
END PLATE
MAIN ROD
IMPORTANT: Flipper plate MUST be completely down
when attaching actuator push rod.
IMPORTANT: Adjust the actuator push rod length so
that the flipper plate is completely down
(engaged position) (Figure 16).
CAM
CLEVIS
CLEVIS PIN
COTTER PIN
™
IMPORTANT: The PosiLok flipper plate assembly should
rotate freely without binding after attaching
the actuator push rod (Figure 16).
4.
On both sides of the end plate, position block up against
the main rod of the flipper plate assembly and securely
weld to underside of end plate (Figure 18). Refer to
manual NS-65-07.
PUSH ROD
ADJUSTING
JAM NUT
CAM BRACKET
16. Air System Connection Overview
1.
2.
1/4"(6 mm) TO 1/3"(8 mm)
CAM MOUNTING HOLE
The PosiLok™ is activated through the trailer’s emergency
brake system. To connect the PosiLok™ to the air system,
locate the trailer emergency air supply line.
CLEVIS MOUNTING HOLE
™
Attach the emergency supply line to PosiLok actuator
inlet port (Figure 18).
“A”
IMPORTANT: It is the responsibility of the air system
installer to secure all air lines and check
for any air leaks. If air leaks are detected,
repair is required.
Failure to eliminate air leaks could
compromise suspension’s performance
which, if not avoided, could result in
component or property damage.
3/8" (9 mm)
MAXIMUM ACTUATOR
PUSH ROD PROTRUSION
ACTUATOR
PUSH ROD
CLEVIS NUT
Figure 18
ACTUATOR
CHAMBER
INLET PORT
FROM THE EMERGENCY
AIR SUPPLY LINE
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AIR LINE FITTING
13
Installation
Air Control Kit
The PosiLok™ flipper plates are activated by the vehicle’s
emergency parking brakes. When the parking brakes are engaged,
the flipper plates rotate down to the engaged position. When
the parking brakes are released, the flipper plates rotate up
to the disengaged position.
1.
If not already present, install air reservoir, mud flap and
stinger brackets. Grind off paint and prepare all surfaces
for welding. Refer to welding standards detailed in
Section 6 of this manual.
2.
Install the air reservoir to the air reservoir brackets.
3.
Plumb the air control system as shown (Figure 19).
The air control system of the CBX40/CBX40 Fusion/CB-4000
and CBX69 suspension uses air drawn from the tractor air
system to pressurize the suspension’s air springs. The suspension,
working with the air control system, provides optimum
suspension performance only when all air control system
components are installed and operating properly.
5.
When the emergency brakes are released, air is supplied
to the air springs, raising the trailer to ride height. This
frees the flipper plates and allows them to rotate up and
out of the way.
6.
After installing the PosiLok™, verify proper ride height
and adjust per Section 16, if needed.
7.
If proper ride height cannot be achieved, troubleshoot
height control valve operation in accordance with Section 19.
8.
The system could contain a dump or exhaust feature.
For information and schematics of this option, contact
SAF-HOLLAND® Customer Service at 888-396-6501.
Optional Air Release System
If the CBX69 was ordered with a slider pull pin air release
system, the air release control valve and the actuator will
need to be plumbed (Figure 19.A).
IMPORTANT: Ensure that all air lines and valves are
free from obstruction through the full
operational range of the suspension.
IMPORTANT: A pressure protection valve (PPV) MUST
be attached to the air reservoir in order to
maintain proper air pressure (Figure 19).
IMPORTANT: The air pressure protection valve maintains
safe brake pressure. Approximately 85 psig
(5.9 bars) opens the valve, and 65 psig
(4.5 bars) closes the valve.
NOTE: When installing pressure protection valve, use
a drop of oil or loctite to lubricate threaded
connections. DO NOT use a pipe compound or
teflon tape as they may clog the valve.
14
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Installation
Figure 19
STANDARD AIR CONTROL SYSTEM
AIR RESERVOIR
PRESSURE PROTECTION
VALVE (PPV)
TO AIR SPRINGS
TO AIR SPRINGS
CONTROL ARM
(NEUTRAL POSITION)
TO GLAD
HAND OR
EMERGENCY
BRAKE
AIR SPRING
AIR SPRING
(CBX69 ONLY)
TO AIR SUPPLY
POSILOK™ ACTUATOR
AIR SPRING
(CBX69 ONLY)
TO HEIGHT CONTROL
VALVE (HCV)
AIR SPRING
AIR SPRING
HEIGHT CONTROL
VALVE (HCV)
AIR SPRING
Figure 19.A
OPTIONAL AIR RELEASE SYSTEM
PRESSURE PROTECTION VALVE
TO GLAD HAND OR
EMERGENCY BRAKE
CYL
RESET
N.C.
AIR RELEASE CONTROL VALVE
XL-AS20001BM-en-US Rev B · 2014-04-22 · Amendments and errors reserved. © SAF-HOLLAND, Inc.
SLIDER PULL PIN
RELEASE ACTUATOR
15
Opperation
17. PosiLok™ Engage Procedures
Release air pressure from the trailer brake system or
disconnect the glad hand. This engages the parking brakes
and causes the PosiLok™ actuator to engage, which rotates
the rod so the flipper plates swing down into an engaged
position (Figure 20).
Figure 20
CBX40 FUSION ILLUSTRATED
18. PosiLok™ Disengage Procedures
When the parking brakes are disengaged, the primary height
control valve (HCV) takes full function. When the system
has sufficient air pressure in the suspension air springs, the
actuator extends, rotating the rod so the flipper plates swing
up away from the load pads into a disengaged position
(Figure 21). The vehicle is now ready for movement.
IMPORTANT: DO NOT operate vehicle (put in motion)
if flipper plates are trapped in the down
position (Figure 22). Refer to the
Troubleshooting Section 21.
Failure to adequately raise flipper
plates could result in trailer, suspension
component, and cargo damage.
FLIPPER PLATE IN THE
ENGAGED POSITION
Figure 21
CBX40 FUSION ILLUSTRATED
FLIPPER PLATE IN THE
DISENGAGED POSITION
Figure 22
CBX40 FUSION ILLUSTRATED
FLIPPER PLATE TRAPPED
IN THE DOWN POSITION
16
XL-AS20001BM-en-US Rev B · 2014-04-22 · Amendments and errors reserved. © SAF-HOLLAND, Inc.
Maintenance
19. Ride Height Adjustment
1.
Figure 23
Ensure that the linkage assembled to the height control
valve (HCV) and suspension is the appropriate length
(Figure 23).
CBX40 FUSION ILLUSTRATED
IMPORTANT: A 15" linkage is used for ride heights of
16", 16.5"-17". A 16" linkage is required
for 18" ride heights (Figure 23).
15.5", 16", 16.5" AND
17" RIDE HEIGHTS
REQUIRE 15" LINKAGE
18" RIDE HEIGHT
REQUIRES 16" LINKAGE
Failure to match the linkage length to
the design ride height could result in
improper suspension height which, if
not avoided, could result in damage to
trailer components.
2.
3.
4.
Install service and emergency lines to the slider and
allow the suspension to air up.
Measure the ride height of the suspension (Figure 24)
with a tape measure.
Compare the measured suspension ride height value
to the appropriate value (Table 3). Make sure your
measured ride height value is within ± 1/4" (6 mm).
HEIGHT CONTROL
VALVE ARM
LOWER LINKAGE
CONNECTION
Figure 24
CBX40 FUSION ILLUSTRATED
Table 3
MODEL
“A” RIDE HEIGHT
CBX40/CB-4000/CBX69 - 15.5
CBX40/CB-4000/CBX69 - 16
CBX40/CB-4000/CBX69 - 16.5
CBX40/CB-4000/CBX69 - 17
CBX40/CB-4000/CBX69 - 18
15.5"
16"
16.5"
17"
18"
“A”
RIDE
HEIGHT
IMPORTANT: If the measured ride height value is NOT
within ± 1/4"(6 mm); verify the linkage
length (Table 4 and Figure 23), and
the hole location where the top mounting
stud of the height control valve (HCV) is
bolted to the mounting bracket (Figure 25).
Table 4
RIDE HEIGHT
15.5"
16"
16.5"
17"
18"
Figure 25
HOLE LOCATION
TOP HOLE
2ND HOLE
3RD HOLE
4TH HOLE
4TH HOLE
LINKAGE LENGTH
15"
15"
15"
15"
16"
CBX40 FUSION ILLUSTRATED
HEIGHT CONTROL VALVE
MOUNTING BRACKET
TOP HOLE
2ND HOLE
3RD HOLE
5.
Once proper ride height is achieved, visually check all
air control system fittings for air leaks by applying a
soapy water solution and checking for bubbles at all air
connections and fittings.
XL-AS20001BM-en-US Rev B · 2014-04-22 · Amendments and errors reserved. © SAF-HOLLAND, Inc.
4TH HOLE
17
Maintenance
20. Height Control Valve
Performance Check
Figure 26
IMPORTANT: Proper inspection can eliminate unnecessary
replacement of height control valve.
INTAKE - UP 45°
1.
Apply air system pressure above 85 psig (5.9 bars).
2.
Using multiple jack stands support the vehicle frame
approximately 2" (51 mm) below ride height per OEM
specified locations.
Failure to properly support the suspension
during maintenance could create a crush
hazard which, if not avoided, could result
in death or serious injury.
3.
Detach the lower connection of the link assembly from
mounting bracket.
4.
Move control arm up 45° for 10 - 15 seconds – air should
flow to air spring(s) (Figure 26).
5.
Move control arm to center (neutral) position – valve
should shut off air flow (Figure 26).
6.
Move control arm down 45° for 10 - 15 seconds – air
should exhaust (Figure 26).
7.
Move control arm to center (neutral) position – valve
should shut off air flow.
8.
The valve is operating correctly if it performs as described
in Steps 4 - 7 above.
CENTER
(NEUTRAL)
POSITION
EXHAUST - DOWN 45°
NOTE: If the valve does not perform correctly, replace
the valve.
9.
Re-attach the lower link assembly to mounting bracket,
BOEUPSRVFUPJOMCT/tN
IMPORTANT: If 85 psig (5.9 bars) of air system pressure
cannot be achieved, check pressure
protection valve and vehicle air compressor
to see if they are operating properly. Also,
check the air lines for obstructions caused
by dirt particles, foreign debris, ice, etc.
10. Remove jack stands.
18
XL-AS20001BM-en-US Rev B · 2014-04-22 · Amendments and errors reserved. © SAF-HOLLAND, Inc.
Troubleshooting
21. Troubleshooting
PROBLEM
Trailer is at full extension
and suspension is pulling
on shock absorber.
Flipper plates are trapped
in the down position.
Flipper plates will not
swing down completely
Flipper plates are bent
or buckled
POSSIBLE CAUSE
SOLUTION
No air flow out of pressure protection valve
from the air reservoir.
Check specified air pressure. Minimum 85 psig (5.9 bars) required
in air reservoir. Repair or replace as required, refer to Section 16.
Actuator or HVC valve mis-adjusted
or malfunctioning
Check and adjust or replace as required, refer to Section 20.
HVC valve malfunctioning.
Check HVC valve installation and function Repair or replace as
required, refer to Section 19 and 20.
Actuator push rod is bent.
Replace as required, refer to Section 15.
Cam bracket that connects to actuator is
damaged or weld is broken.
Repair or replace as required.
Actuator diaphragm is ruptured.
Replace as required, refer to Section 15.
No air flow out of pressure protection valve
from the air reservoir.
Check specified air pressure. Minimum 85 psig (5.9 bars) required
in air reservoir, refer to Section 16.
Air flow to either the pilot valve or to the
HVC valve does not exhaust.
Check for breech in air supply line and repair or replace as required,
refer to Section 16.
Vehicle overloaded or unevenly loaded.
Check loads and correct as needed.
HCV mis-adjusted or malfunctioning.
Check and repair or replace as required (Refer to manufacturer’s
HCV manual), refer to Section 19 and 20.
Trailer not at proper ride height.
Check and adjust HCV if needed, refer to Section 19.
Cam bracket that connects to
actuator is damaged.
Repair or replace as required.
Ride height set improperly (too low).
Adjust ride height, refer to Section 19.
Less than 1" (25 mm) gap between top of
the equalizing beam and the bottom of the
flipper plate.
Adjust ride height, refer to Section 19.
Actuator push rod need adjustment.
Check and adjust, refer to Section 15.
Moving trailer through rough yard without
waiting for the suspension to air up.
Replace bent or buckled flipper plates, refer to Section 14.
Trailer loaded with heavy fork/load
combination with slider in forward position.
Improper ride height setting due to load or
lowering trailer for bridge height.
Overload of rear suspension caused by yard
horse raising front of trailer too high and
moving trailer to and from dock.
Temporary loss of ride height when slider is
moved at a high rate of speed and engaging
emergency brakes.
XL-AS20001BM-en-US Rev B · 2014-04-22 · Amendments and errors reserved. © SAF-HOLLAND, Inc.
19
From fifth wheel rebuild kits to suspension bushing repair kits,
SAF-HOLLAND Original Parts are the same quality components used
in the original component assembly.
SAF-HOLLAND Original Parts are tested and designed to provide
maximum performance and durability. Will-fits, look-alikes or, worse
yet, counterfeit parts will only limit the performance potential and
could possibly void SAF-HOLLAND’s warranty. Always be sure to spec
SAF-HOLLAND Original Parts when servicing your
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XL-AS20001BM-en-US Rev B · 2014-04-22 · Amendments and errors reserved. © SAF-HOLLAND, Inc.
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